Multi-phasic integrated super-intensive shrimp production system

ABSTRACT

A method for shrimp aquaculture, in which, all growth phases and essential operations are modularized and integrated to form a multi-phasic synchronous super-intensive shrimp production system controlled by a custom designed cyber-physical platform. Modular components include: post-larvae nursery module(s), grow-out production module(s), recirculating aquaculture system (RAS) module(s), feed distribution module(s) and regulatory elements comprised of Program Logic Controllers (PLCs) integrated with Human Interface Modules (HIMs).

RELATED APPLICATIONS

This application claims priority to PCT/US2016/017588 titled“MULTI-PHASIC INTEGRATED SUPER-INTENSIVE SHRIMP PRODUCTION SYSTEM,”having M. Kemp and A. Brand listed as inventors, filed on 11 Feb. 2016(11 Feb. 2016). The PCT application claiming priority to U.S.provisional application No. 62/140,392 filed on 30 Mar. 2015 having thesame title and inventors.

FEDERALLY SPONSORED RESEARCH

No federal funds were used in the development of the present invention.

JOINT RESEARCH AGREEMENTS

Not Applicable.

SEQUENCE LISTING

Not Applicable.

BACKGROUND

Aquaculture is at a crossroads. Facing the pressure of driving higherrates of production per unit area, aquaculture has the opportunity tolearn from the mistakes of others and embrace sustainable managementpractices. This young industry's long-term success and economicviability depends on innovation and solutions aimed at tackling thetriple sustainability challenge of disease, waste and feed in parallelwith its current explosive global demand driven expansion. World-wideshrimp production practices are unsustainable because of:

Climate and geographic restrictions

Ecological Limitations—land destruction

Feed Concerns—fishmeal content

Labor Abuse and social breakdown

Shrimp Disease—Acute Hepatopancreatic Necrosis Syndrome (APNS) or EarlyMortality Syndrome (EMS), Taura virus, White spot virus (WSSV),enterocytozoon hepatopennai (EHP) caused by fungi, etc.

Human Health Concerns (feed additives including banned chemicals andantibiotics)

Processing—Sanitation procedures or lack thereof

Locavore movement and lifestyle

Expanding on the above, Shrimp are the most preferred seafood consumedin the US. However, there is a huge disparity between domestic demandand domestic supply resulting in a reliance on imported products and agrowing federal trade deficit in shrimp. In addition to concerns aboutthe quantity of shrimp imported into the US, the quality of importedshrimp may be inferior to domestically grown shrimp and there are humanhealth concerns about antibiotic residues that are shown to be presentin some imported products. The US Food and Drug Administration ischarged with inspecting seafood imported into the US, but this agency isonly able to inspect a small percentage of products that make their wayinto US markets.

In light of a growing federal trade deficit in shrimp products, andconcerns about food safety, there are compelling reasons to support a USshrimp farming industry. Expanding the US shrimp farming industry usingtraditional approaches is not feasible due to concerns aboutenvironmental pollution, disease transmission, cost of production andclimatic issues. Traditionally, shrimp have been cultured in coastalponds where flow-through water exchange is used to maintain acceptablewater quality. However, influent water can serve as a vector forvirulent shrimp pathogens and pond effluent can adversely affect coastalwater quality. In addition, expanding shrimp farms in coastal areas maycause multiple-use conflicts and traditional shrimp farms are restrictedto more southern latitudes because of the warm-water requirements ofshrimp (Moss, S. M., “Shrimp Aquaculture,” The Research, Education, andEconomics Information System (REEIS) of the U. S. Department ofAgriculture (USDA), Oceanic Institute Makapuu Point, 1 Aug. 2010, Web,31 Jul. 2012).

With respect to sustainability of land based industrial shrimp farming,things drastically changed around three decades ago with theintroduction of land based aquaculture, particularly in Southeast Asiaand Latin America. Aquaculture processes changed from traditional,small-scale and low-impact to industrial, large-scale, high-impactproduction approaches, with seafood export, not local use, in mind. Asthe industry expanded its reach into the international marketplace, therate of destruction of the natural environment and the related adverseconsequences for local communities accelerated. The ecological footprintincreased logarithmically and destruction followed. Along withenvironmental destruction, incidence of disease followed: Taura virus,White spot virus (WSSV), Infectious Hypodermal and Hematopoetic NecrosisVirus (IHNNV), Acute Hepatopancreatic Necrosis Syndrome (APNS) or EarlyMortality Syndrome (EMS) caused by bacteria, and enterocytozoonhepatopennai (EHP) caused by fungi, etc.

The history of shrimp farming in the United States is both brief andvolatile. Feasibility of growing Pacific white shrimp (Litopenaeusvannamei) in the United States on an industrial scale was demonstratedthree decades ago, with this development, shrimp farming in the U.S.became commercially achievable in the early 1980s with increasingproduction levels obtained until the early 2000s. The first technologythat allowed for widespread farming in the U.S. was the single phasesemi-intensive pond model, in which post-larvae obtained from thehatchery are directly stocked into the ponds. Using this processproduction of 5-10 MT/ha/crop could be achieved. However, only one cropper year could be produced because of climatic conditions. Thus, shrimpfarming in the United States became economically non-competitiverelative to tropical areas where multiple crops per year are the norm.This has resulted in a rapid decline in shrimp farm production in theU.S. since the early 2000s. In effect shrimp production moved offshore.Today the United States consumes >600,000 tons of shrimp per year. Wildcapture and farmed shrimp fill <3% of the USA demand. US shrimp importvalue climbed 67% in 2014. Domestic aquaculture meets “<1%” of Americanconsumption.

Despite the seeming advantages of shrimp production in the tropics,there are untenable issues. Production in the tropics is notsustainable, nor is it consistent with the locavore movement.Increasingly people throughout the world do not trust the source oftheir food because production is favored at all costs even if it meansadulteration with harmful chemicals or unsanitary processing of theproduct. Aside from the distrust, there is recognition that food shouldbe produced in a sustainable manner and current technology does notreflect this driving force.

It was recognized more than a decade ago that change was essential givenAmerican demand. American Federal and State Governments bordering theGulf of Mexico and southern Atlantic region supported research directedtowards development of a new technology that will allow U.S. farmers tocompete with year-round production in the tropics. In essence newtechnology had to be developed and implemented.

Any technologic development(s) must accommodate geographic and climaticdemands, i.e., land use should be minimized and environmentalmodification (temperature) necessary for shrimp growth must not beenergy intensive. The only way this could be accomplished was to situateproduction indoors, i.e., inside structures such as enclosed warehouses.In turn this allowed production closer to the consumer, whether thatperson is an American or any other citizen of the world. However, simplyreplicating pond growing conditions indoors was not acceptable becausewarehouse structures would have to be enormous, i.e., occupy many acres(hectares) and be energy intensive. In order to minimize issuesdescribed above, vertical farming techniques has been considered.

Description of vertical aquaculture in stacked raceways dates back to atleast 1973. Durwood Duggar pointed out that King James used stackedraceways in the 80s to culture shrimp (Duggar, D., Title “IntensiveShrimp Production Economic Challenges” BioCepts International, Inc.,Web, 29 Sep. 2011). Even before that, Ron Wulff and Durwood Duggardeveloped a stacked raceway system in 1973 for the Ralston PurinaMariculture Research Center's intensive shrimp production efforts.Beyond shrimp aquaculture, fish aquaculture using water as shallow as 10cm in stacked raceways for hyper-intensive fish farming, has beenpracticed since at least 2001 (Oiestad V. “Hyper-Intensive Fish Farming,Shallow Raceways Save Space, Water,” Global Aquaculture Alliance, Web,2001). Although vertical stacking for aquaculture having been described,the challenge remains how to put such a space saving model intoindustrial production and practice. Remaining to be resolved was energyconservation issues, structural engineering issues, maintenance of waterquality, temperature, dissolved oxygen, feed distribution and how tointegrate the process while maintaining control. Such problems have beenresolved with the current invention, wherein the basic operations ofshrimp production are modularized and integrated to form a multi-phasicsynchronous super-intensive shrimp production system controlled by acustom designed cyber-physical platform that acquires data throughsensors embedded in the production sub-unit module, recirculatingaquaculture system (RAS) module, and feed distribution module, allowingcontrol of one or more equipment devices communicating with the ProgramLogic Controllers (PLC's) integrated with Human Interface Modules (HIMs)through coupled feed-back loops for maintaining an aquacultureenvironment for a synchronous production cycle of shrimp.

SUMMARY

The present disclosure generally pertains to the design and integrationof modular components including a nursery, stacked production assembly,water recycling aquaculture system (RAS) and feed distribution equipmentalong with computer control equipment into a multi-phasicsuper-intensive shrimp production system that operates synchronously,allowing for 12 to 17 production cycles (crops) per year. The integratedsystem is designed to eliminate production constraints inherentlypresent from the time post larvae (“PLs”) are stocked until shrimp areharvested at completion of grow-out thereby maximizing through-put.

Central to any production model is the carrying capacity or biomass perunit area the system can support. Research has shown that shrimp can begrown consistently at a biomass of 4 kg/m² in shallow water tanks. Whenthis limitation is applied to a single phase production system, such asa land based pond, tank or raceway, the biomass at the end of thegrow-out cycle is a determinant of how much shrimp can be produced.Therefore, while thousands of PLs can be stocked and still not exceed abiomass of 4 kg/m² initially, the carrying capacity will be quicklyexceeded and the system will crash. A multi-phasic synchronousproduction system alleviates this constraint since carrying capacity ofthe system is not exceeded at any stage or phase of the productioncycle, i.e., from stocking to harvest.

Operating from a conservative perspective, one of many possible shrimpproduction models based on a biomass of ˜3 kg/m² and a multi-phasicproduction cycle, is presented in FIG. 1 and Table 1. In this model,four phases are employed. In practice Phase 1 is executed by stockingPLs into a nursery where they are raised to a juvenile stage (0.7-1 g)for ˜1 month (Table 1). Phase 2 is executed by transferring the juvenileshrimp to production subunit #1, otherwise known as a raceway, of theproduction module. When the biomass begins to exceed carrying capacityof the system, i.e., after ˜4 weeks of growth, the shrimp density isreduced by sub-dividing the shrimp evenly between production sub-units#2 and #3 (Phase 3). Transfer is accomplished by gravity, i.e., aconnecting tube is installed between production subunit #1 and #2 orsubunit #1 and #3. Shrimp suspended in water are moved from the superiorproduction sub-unit, i.e., #1, to the descendent #2 or #3 productionsub-units by gravity. Integral to establishing a synchronous productioncycle, as soon as #1 is emptied it is restocked with juvenile shrimptransferred from the nursery in order for the cycle to be reinitiated.

After ˜4 additional weeks, the carrying capacity of #2 and #3 have beenexceeded. The shrimp biomass cannot just be reduced by sub-dividingcontents into #4 and #5. The carrying capacity or biomass of the nextphase should be considered. At the end of the monthly cycle the weightof each shrimp will have increased substantially. This being the case,shrimp numbers should be reduced. The shrimp number is reduced in thiscase by evenly dividing the contents of Sub-unit No. 3 into sub-unit No.4 and No. 5. Likewise the shrimp contents of sub-unit No. 2 is evenlydivided into sub-units No. 6 and sub-unit No. 7. After an additionalperiod, i.e., ˜4 weeks, shrimp weighting ˜26 g are harvested fromsub-Units Nos: 4, 5, 6 and 7 and can be offered for sale.

Alternatively, a five phase model can be employed (see FIG. 2). In thismodel, Phase 1 is executed by stocking PLs into a nursery where they areraised to a juvenile stage (0.7-1 g) for ˜1 month. Phase 2 is executedby transferring the juvenile shrimp to production sub-unit #1 of theproduction module. The same thing applies to the five phase model as thefour phase model described above, i.e., when the biomass begins toexceed carrying capacity of the system, i.e., after ˜4 weeks of growth,the shrimp density should be reduced. This is accomplished bysub-dividing the shrimp evenly between production sub-units #2 and #3(Phase 3). After ˜4 additional weeks, the carrying capacity of #2 and #3will again have been exceeded. The shrimp numbers cannot simply bereduced by transferring the contents of #2 and #3 to #4 and #5 becausein a short period of time the carrying capacity of #4 and #5 will begreatly exceeded. Instead a partial harvest of shrimp should be carriedout and the remainder of the shrimp in #2 and #3 can then be transferredto #4 and #5. After an additional period, i.e., ˜4 weeks, anotherpartial harvest is executed for the reasons described above and theremainder of the shrimp in #4 and #5 are transferred to #6 and #7,respectively, for final grow out. When in synchronous production shrimpweighting around 15, 24 and 30 g can be offered for sale at the end ofeach monthly cycle. Using the model described, 13 shrimp crops can beproduced per year.

Whether a four or five phase model is employed, both are dependent onunderstanding the chemical, physical and biological conditions necessaryfor shrimp culture. Being heterotherms, Litopenaeus vannamei (Pacificwhite-leg shrimp) should be maintained at sustainable temperatures inthe range of about 21° C.-37° C. However, even more importantlytemperature should be highly regulated to maximize life functions. Forpractical purposes this means the environmental temperature should bemaintained within a narrow range of 30-32° C., with 31° C. beingpreferred. The temperature constraints in most climatic areas includingthe tropics impose conditions outside the optimal. In addition toenvironmental temperature, water quality is central to shrimpproduction. Three different approaches have been employed: these includea non-recirculating system, a recirculating aquaculture system (RAS),and a refined flow through system from a natural source. While there aremany variations in terms of aquaculture, all shrimp systems must addresswater quality issues with respect to salinity, solid waste removal,dissolved oxygen control, ammonia-nitrogen control, carbon dioxidecontrol, pH (alkalinity). The only system that allows for control as itrelates to the current disclosure is a RAS variant.

An understanding of the chemical, physical and biological conditionsnecessary for shrimp culture, allowed shrimp farming to rapidly developin the USA. However the history of shrimp farming in the United Statesis both brief and volatile from an economic perspective. Pacific whiteshrimp (Litopenaeus vannamei) was quickly and widely accepted as themost feasible species for large-scale shrimp production in the UnitedStates. Shrimp farming in the U.S. rapidly expanded in the early 1980swith increasing production levels until the early 2000s. The firsttechnology that allowed widespread farming in the U.S. was the singlephase semi-intensive pond model, in which PLs obtained from a hatcherywere directly stocked in ponds. Using this process, production levels of5 plus metric tons per hectare per crop (MT/ha/crop) were obtainable.However, due to climatic considerations only one crop was possible peryear. Relative to tropical shrimp farming practices American farms werenon-competitive. Shrimp farming moved offshore and a rapid decline inland based shrimp farm production in the U.S. since the early 2000sfollowed.

Recognition of the circumstances delineated above motivated researchersto develop technology that will allow U.S. farmers to counter theeconomic advantages of year-round production in the tropics. Technologydescribed in U.S. Pat. No. 8,336,498, was developed in part to addressthese issues.

The technology described in U.S. Pat. No. 8,336,498, is limited in scopeand deals with a subset of aspects related to shrimp production. Stackedraceways were used for shrimp aquaculture as early as 1973 and morerecently have become standard practice in fish aquaculture (see above).Stacked raceways by themselves are simply one factor in the design of anintegrated systems approach to shrimp aquaculture as disclosed herein.

All aquaculture systems (i.e. ponds, tanks or stacked raceways, etc)contain physical and biological limitations as to the number andbiological mass of shrimp that can be grown per square meter of waterfootprint. Many factors go into this limitation and generally relate tothe chemical and physical stress placed on the shrimp. A multi-phasicapproach to production of shrimp is designed to mitigate stress andcarrying capacity limitations.

Thinking inside the box, the present disclosure relates generally todesign and operation of an integrated multi-phasic super-intensiveshrimp production system comprised of modular sub-units. Thesub-components are designed to be assembled in structural unitscomprised of inter-modal shipping containers, freight containers or seacans constructed of reusable steel, or similar types of structures. Allsub-units are purpose built as are the inter-modal shipping containersthat are made for efficient secure storage, structurally rigid andstackable.

The modules are custom designed and include a shrimp nursery for PLs,production assemblies comprised of production sub-units fabricated andconstructed in rigid self-supporting containers, a recycling aquaculturesystem (RAS) for processing water, a computer controlled feeddistribution system and computer station connected to each module foroperation of the integrated multi-phasic shrimp production system.

Embodiments of the current disclosure may achieve one or more of thefollowing advantages:

Aquaculture of shrimp using a total water volume per weight of shrimpproduced significantly less than with conventional techniques.

Aquaculture of shrimp in significantly lower average water depths (e.g.as low as 2.5 cm, or 2-3 times lower) than conventional techniques.

Aquaculture of shrimp using significantly less area (e.g. floor space)per weight of shrimp than obtained with conventional techniques.

Aquaculture of shrimp achieving significantly greater shrimp productionper m² of water footprint, i.e., >100 kg shrimp/m² of waterfootprint/yr. Stated another way, production capacity is >1,000,000kg/ha water footprint/yr.

Aquaculture of shrimp at higher densities per square meter than obtainedwith conventional techniques.

Aquaculture of shrimp achieving significantly greater survival,i.e., >80% survival, even at production levels greater than 100 kg/m² ofwater footprint.

Aquaculture of shrimp using feed system optimize for growth.

Aquaculture of shrimp using a feed system that allows feeding of shrimpto satiation 24 hr. a day.

Aquaculture of shrimp using a feed system allowing for appropriate sizefeed proportional to weight of shrimp.

Aquaculture of shrimp using a floating feed manufactured using extrusioncooking.

Aquaculture of shrimp using a computer controlled point distributionsystem.

Aquaculture of shrimp using advanced engineering that deploys a customcyber-physical platform developed for environmental sensing including:water temperature, salinity, dissolved oxygen, turbidity, nitrogencontaining metabolites, acoustic sensors (level of feed consumption),etc.

Aquaculture of shrimp using equipment engineered and designed to isolateproduction from the environment so as to allow for operationsindependent of geographic and climatic restrictions.

Aquaculture of shrimp in vertically stacked production sub-unitsinstalled in inter-modal containers thereby allowing for rethinkingstructural support equipment and design.

Aquaculture of shrimp using synchronous production cycles. Production nolonger is a batch process.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete and through understanding of the present embodiments andadvantages thereof may be acquired by referring to the followingdescription taken in conjunction with the accompanying drawings, inwhich like reference numbers indicate like features and wherein:

FIG. 1 shows a flow diagram for four phase super-intensive shrimpproduction model. The Phase 1 Nursery (1101) is in fluid communicationwith Phase 2 Production Subunit 1 (1201). Phase 2 Production Subunit 1(1201) is in fluid communication with Phase 3 Production Subunit 2(1301) and Phase 3 Production Subunit 3 (1401). Phase 3 ProductionSubunit 2 (1301) is in fluid communication with Phase 4 ProductionSubunit 6 (1701) and Phase 4 Production Subunit 7 (1801). Phase 3Production Subunit 3 (1401) is in fluid communication with Phase 4Production Subunit 4 (1501) and Phase 4 Production Subunit 5 (1601).

FIG. 2 shows a flow diagram for five-phase super-intensive shrimpproduction model. The Phase 1 Nursery (2101) is in fluid communicationwith Phase 2 Production Subunit 1 (2201). Phase 2 Production Subunit 1(2201) is in fluid communication with Phase 3 Production Subunit 2(2301) and Phase 3 Production Subunit 3 (2401). Phase 3 ProductionSubunit 2 (2301) can be subjected to a partial harvest (2310) and is influid communication with Phase 4 Production Subunit 4 (2501). Phase 3Production Subunit 3 (2401) can be subjected to a partial harvest (2320)and is in fluid communication with Phase 4 Production Subunit 5 (2601).Phase 4 Production Subunit 4 (2501) can be subjected to a partialharvest (2330) and is fluid communication with Phase 5 Productionsubunit 6 (2701). Phase 4 Production Subunit 5 (2601) can be subjectedto a partial harvest (2340) and is fluid communication with Phase 5Production subunit 7 (2801).

FIG. 3A illustrates a partial see through side view of an inter-modalcontainer showing stacked nursery tanks used for culture of shrimppost-larvae and location of support equipment. FIG. 3B illustrates anexterior side view of an inter-modal container showing location ofaccess panels and doors used for service access. FIG. 3C illustrates theend-view an inter-modal container with the doors shown. FIG. 3D shows across-section through stacked nursery tanks constructed in aninter-modal container, viewed from an end perspective. FIG. 3Eillustrates an enlargement of the right half of FIG. 3A allowing forincreased detail.

FIG. 4 shows a preferred inter-modal container with exterior dimensionsindicated.

FIG. 5 illustrates a schematic of a cross-section of two inter-modalcontainers stacked and the production sub-units vertically arrangedwithin.

FIG. 6 illustrates a partial see through side view of an inter-modalcontainer showing production sub-units arranged vertically in twostacked inter-modal containers. The harvest pit is shown at the leftside along with access doors arrayed above the water level of eachproduction sub-unit.

FIG. 7A illustrates a production sub-unit viewed from above. Alsoillustrated is the directional flow of water within. FIG. 7B illustratesa cross-section along the linear axis of the harvest pit located at theleft end of FIG. 7A. FIG. 7C illustrates a detailed view of the harvestpit along the production sub-unit axis to the left of FIG. 7A.

FIG. 8A illustrates the stainless steel wire fabricated as to form asub-frame over which 100 mil high density polyethylene HDPE) is arrangedto form a water compartment. FIG. 8B illustrates a cross-section througha production sub-unit showing details of a cross brace to which supportbrackets attached. Support brackets support the weight of the productionsub-unit when welded to the wall of an inter-modal container.

FIG. 9 illustrates a detailed flow diagram of the recycling aquaculturesystem (RAS) designed as a module to be operated as part of theintegrated multi-phasic production system.

FIG. 10 shows a detailed schematic of a computer controlled feeddistribution system designed to distribute size appropriate feed toproduction sub-units.

DEFINITIONS

A programmable logic controller (PLC) is an industrial computer controlsystem that continuously monitors the state of input devices and makesdecisions based upon a custom program to control the state of outputdevices. Almost any production line, machine function, or process can begreatly enhanced using this type of control system. However, the biggestbenefit in using a PLC is the ability to change and replicate theoperation or process while collecting and communicating vitalinformation. Preferred PLC's of this invention include 1-12 digitalinputs; 1-18 digital outputs; 1-12 analog inputs (0-12 volts); analogoutputs, thermocouples; RS232 interface; USB interface. Using a PCL thatis commercially available from Velocio Networks Inc (Huntsville, Ala.) auser can use software to have: Process control, Machine control, Motionsystem control, Automated Test, Home automation. The description of PCLand/or their equivalents are discussed in the data sheets for the ACE,BRANCHED, EMBEDDED products (See Branch PCL, Velocio Networks Inc,Huntsville Ala., pg 1-6, 2014; and Ace PCL, Velocio Networks Inc,Huntsville Ala., pg 1-6, 2014).

Electrical communication as understood in this invention iscommunication in which any type of information (speech, alphanumeric,visual, data, signals, or other type of information) is transmitted byelectric signals propagated over wires or wirelessly (i.e. radiosignals, UV, optical, cell phone, and the like). Depending on the meansused to transmit or carry the signals, electrical communication may beclassified as wire or wireless. Wire communication is often used in manysystems in combination with different forms of radio communication, forexample, with radio-relay communication and satellite communication.According to the classification of the International TelecommunicationUnion, electrical communication also includes the transmission ofinformation by optical and other electromagnetic systems.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Desiring to meet the pressure of driving higher rates of production perunit area along with minimizing costs, a multi-phasic super-intensiveshrimp production system comprised of modules conceived along functionallines was devised. The foremost consideration was that each functionalmodule had to be designed such that it could be integrated into thewhole. In addition, all modules were designed from the perspective ofoffsite manufacturing and rapid onsite assembly.

Disclosed herein is an integrated multi-phasic super-intensive shrimpproduction system that utilizes a first phase shrimp nursery andproduction units comprised of stacked production sub-units for shrimpgrow out, both employing a clear water closed loop RecirculatingAquaculture System (RAS) designed to maximize through put whileminimizing production costs. The integrated shrimp production systemalso includes a computer controlled feed distribution system, aregulated pressure driven aeration system, a custom designedcyber-physical platform for environmental sensing including: watertemperature, salinity, dissolved oxygen, turbidity, nitrogen metabolites(ammonia, nitrites, nitrates), acoustic sensors (feeding activity) andreal-time visual monitoring of each production sub-unit using CCTVcameras for conditions associated with each production sub-unit(aeration, circulation, feed utilization, harvesting, etc.).

Programmable Logic Controller and User Interface.

A programmable logic controller, PLC, or programmable controller is adigital computer used for automation of typically industrialelectromechanical processes, such as control of machinery. PLCs are usedin many machines, in many industries. PLCs are designed for multiplearrangements of digital and analog inputs and outputs, extendedtemperature ranges, immunity to electrical noise, and resistance tovibration and impact. Programs to control machine operation aretypically stored in battery-backed-up or non-volatile memory. A PLC isan example of a “hard” real-time system since output results must beproduced in response to input conditions within a limited time,otherwise unintended operation will result. One having ordinary skill inthe art understands that PLC's together with a Human Interface Modulesallows human interaction with the machines for the effective operationand control of a machine from the human end, whilst the machinesimultaneously feeds back information that aids the operators' decisionmaking process. The user interface, in the industrial design field ofhuman-machine interaction, is the space where interactions betweenhumans and machines occur. Siemens (Siemens Corporation, Washington,D.C., USA), Allen Bradley-Rockwell (Milwaukee, Wis., USA), Manufacturersinclude: YSI by Xylem (Pointe-Claire, Québec, Canada), Pentair Aquatic(Sanford, N.C., USA), Campbell Scientific (Logan, Utah, USA), AQ1(Hobart, Tasmania, Australia), Ametek (Berwyn, Pa., USA), Hach(Loveland, Colo., USA) and other custom automation systems having PLC'sequipment available that would be within the spirit and scope of theinvention.

Sensors/Probes:

Monitoring pH. A pH detector is a device used for potentiometricallymeasuring the pH, which is either the concentration or the activity ofhydrogen ions, of an aqueous solution. Other methods and instruments areused for pH determination that can also be utilized for this invention.Paper capable of indicating pH may also be used. Many commercialproducts are available providing multiple and different means for probesand sensors used for determining the pH, each of which are within thespirit and scope of this invention.

A Water Temperature Sensor/probes: a variety of sensors for measuringwater temperature are available. Generally, the electrical signalstransmitted from the sensors/detectors can be logged and converted todifferent units of measurement, including ° C., ° F., and ° K. Manycommercial products are available providing multiple and different meansfor probes and sensors used for determining temperature, each of whichare within the spirit and scope of this invention.

A Salinity Sensor easily and precisely measures the total dissolved saltcontent in an aqueous solution. The Salinity Sensor is capable ofmeasuring water with a wide variety of salinities, from brackish waterto ocean water, and even hyper-saline environments. Many commercialproducts are available providing multiple and different means for probesand sensors used for determining salinity, each of which are within thespirit and scope of this invention.

Dissolved oxygen sensors. The Dissolved Oxygen Probe can be used toperform a wide variety of experiments to determine changes in dissolvedoxygen levels, which are one of the indicators of the quality in anaquatic environment. Dissolved oxygen refers to the level of free,non-compound oxygen present in water or other liquids. It is animportant parameter in assessing water quality because of its influenceon the organisms living within a body of water. Many commercial productsare available providing multiple and different means for probes andsensors used for determining dissolved oxygen each of which are withinthe spirit and scope of this invention. For example, the online catalogof “direct industry” dot COM includes a large variety of dissolvedoxygen probes. Additionally, Mettler-Toledo Ingold Inc, (Billerica,Mass. 01821 USA) is one of many companies that sells oxygen sensors andprobes that serve as useful oxygen sensor for the current invention.

Turbidity sensors. Turbidity is the cloudiness or haziness of a fluidcaused by large numbers of individual particles that are generallyinvisible to the naked eye, similar to smoke in air. The measurement ofturbidity is a key test of water quality. Many commercial products areavailable providing multiple and different means for probes and sensorsused for determining turbidity, each of which are within the spirit andscope of this invention. For example, an online catalog of called“direct industry” dot com includes a variety of turbidity sensors.Additionally, Mettler-Toledo Ingold Inc, (Billerica, Mass. 01821 USA) isone of many companies that sells turbidity sensors and probes that couldbe useful turbidity sensors for the current invention.

Nitrogen metabolites (ammonia, nitrites, nitrates) detection. Nitrogenis a critical chemical element in both proteins and nucleic acids, andthus every living organism must metabolize nitrogen to survive. Manycommercial products are available providing multiple and different meansfor probes, sensors and detection used for determining nitrogenmetabolites, each of which are within the spirit and scope of thisinvention.

Acoustic sensors (feeding activity) Surface acoustic wave sensors are aclass of microelectromechanical systems (MEMS) which rely on themodulation of surface acoustic waves to sense a physical phenomenon. Thesensor transduces an input electrical signal into a mechanical wavewhich, unlike an electrical signal, can be easily influenced by physicalphenomena. The device then transduces this wave back into an electricalsignal. Changes in amplitude, phase, frequency, or time-delay betweenthe input and output electrical signals can be used to measure thepresence of the desired phenomenon. Many commercial products areavailable providing multiple and different means for probes and sensorsused for determining feeding activity, each of which are within thespirit and scope of this invention.

Cameras. Real-time visual monitoring of each production sub-unit usingCCTV cameras for conditions associated with each production sub-unit(aeration, circulation, feed utilization, harvesting, etc.). Manycommercial products are available providing multiple and different meansfor monitoring production visually, each of which are within the spiritand scope of this invention. Infrared CCTV is also a viable option. Inpreferred embodiments, a Water Proof BW® 700TVL was used (BW Group,China) and a Hikvision DS-2CD2012-I-4MM 1.3MP Outdoor Bullet IPCamera—(Hikivision, City of Industry, Calif., USA).

Sound Feeding System. An SF200 sensor based feeding control system forshrimp farmers was used with the current invention. The system usespassive acoustics to identify shrimp feeding activity and then uses thatinformation to control temporal feed delivery via an adaptive feedingalgorithm. The adaptive algorithm ensures feed delivered matches shrimpappetite so that all animals are fed fully without waste 24 hours a dayif required. Other feeding systems that are not as elaborate are alsoconsidered to be within the spirit and scope of the invention.

Nursery Module

Post-larvae (PL) numbers required to meet production levels laid out inTable 1 above are high. Therefore, demands placed on a nursery phaseexecuted separate from grow out phases are high. To meet thisrequirement, a high capacity nursery module had to be devised.

Disclosed herein shrimp PLs are stocked into tanks stacked vertically ina Conex, at a density of 4,000-8,000/m². Each tank contains water of thesame salinity as that used in pre-equilibration of the PLS. The water ineach tank is maintained by circulating it through a recirculatingaquaculture system (RAS) similar to that described below for ProductionModules (see RAS Module). Water is continuously aerated and maintainedat 31-33° C.

According to one embodiment of the disclosure PLs may be stocked intostacked shallow water tanks, FIGS. 3A, D and E (601), stacked verticallyin a Conex, at a density of 5000-12.000/m². Tanks can be fabricated frommany different materials including fiberglass, wood composites,synthetic plastics, (such as polyethylene, propylene, acrylonitrilebutadiene, styrene, etc.), epoxy coated steel, metals, and combinationthereof. In one desired consideration tanks are fabricated fromacrylonitrile butadiene styrene (ABS) with a 0.5-1.5% slope to a frontcorner wherein a stand-pipe is situated. Prior to installation of thetanks all surfaces on the interior of the Conex of the container (Conex)are completely sealed with a chemical resistant material, example epoxy,to prevent salt water corrosion.

The salt water depth in each tank 601 (FIGS. 3A, D and E) is maintainedat an average depth of 30-50 cm, preferably 40 cm. Tank water depth ineach tank is independently maintained using a stand-pipe plumbed throughthe wall of the Conex into the equipment compartment (602) in which, PLSare stocked. During the PL culture a diverter valve and pump willmaintain water levels by circulation from storage tanks (606).

Heating and/or cooling equipment is centrally located in the equipmentcompartment built into each Conex 602 (FIG. 3A). The temperature in eachtank is maintained by circulating fluid medium maintained at 31-33° C.through a hydronic system consisting of polyethylene (PEX) tubingfastened to the bottom of each nursery tank. This circulation is totallyindependent of the tank contents.

For aeration purposes, air is pre-conditioned to 31-33° C. using a heatexchanger located in equipment compartment 602 (FIG. 3A) then disbursedinto the water in the PL tanks 601 (FIGS. 3A, D and E).

A computer controlled actuator controls feed distribution that isflushed into the tank(s) through tubes 608 (FIG. 3A) connected to ahopper located between tank stacks located in door accessiblecompartments to the left and right of the equipment compartment 607(FIG. 3B). Of note are panels cut into the left and right side of thefront and opposite side from the front (backside) of a Conex 604 (FIG.3B). These panels allow access to each nursery tank since they arelocated above the edge of each tank. They are there for the purpose ofscreen placement in each tank that increases surface area and act asbaffles in the tanks. In addition, after each cycle the tanks need to becleaned and the panel cut outs allow ready access. Each panel cut outunder operating conditions is sealed by a gasket around the door. Thedoor is locked when not needed for access.

The panel shown in 603 (FIG. 3E) is a cover for the equipmentcompartment. Similarly, 605 (FIG. 3C) show the doors located at each endof the Conex.

The nursery phase can be carried out for 25-40 days, preferentially 30days. At the end of this period, PLs have developed into 0.4-0.7 gjuvenile shrimp. The timing can be varied somewhat. Circumstances may besuch that it is desirable to accelerate or slow down shrimp growth, thiscan in part be established by adjusting the water temperature and orfeed rate up or down.

At the end of the nursery phase the juvenile shrimp can be quantifiedand transferred to a production module for grow out.

Grow Out Production Module

A defining limitation when considering shrimp production in a warehouseis the water footprint, i.e., the area occupied by water at groundlevel. The multi-phasic system disclosed herein allows for productionof >100 kg/m² of water footprint per year (see Table 1 above) an amountsignificantly greater than any other system. It is more than ten timesthe quantity that can be grown per m² in single phase productionsystems, such as in ground raceways or above ground tanks.

Cultivation of shrimp in land based tanks or ground situated raceways,typically requires an average water depth of approximately one metermaking the weight prohibitive for application in stacked systems.However, as disclosed in U.S. Pat. No. 8,336,488, shrimp can becultivated at average water depths as low as 10 cm, making it possibleto stack production sub-units and thereby allowing for increased shrimpproduction per water footprint, i.e., the area of occupied ground level.

According to a more specific embodiment disclosed herein is a design fora super-intensive multi-phasic shrimp production module that utilizesspecialized production sub-units integrated into two stacked “Hi-cube”(HC) Conex units. HC Conex units typically have doors fitted at each endand are constructed of corrugated weathering steel (FIG. 4). Each HC canbe stacked and have castings with openings for twist lock fastenerslocated at each corner. For purposes disclosed herein each unittypically has a height of 9 feet 6 inches (2.896 m) and a length of 53ft. (16.15 m). When stacked the height of two Conex containers is 19 ft.(5.79 m).

According to another embodiment of the disclosure, shrimp may be grownin series of stacked production sub-units fabricated in Conexcontainers. Accommodated within each production sub-unit is water of lowaverage depth for growing shrimp. One such design is presented in FIG. 5showing a second inter-modal container (5100) stacked on top of a firstintermodal container (5200). A cross-section through two inter-modalcontainers in which the production sub-units vertically arranged withinis shown in FIG. 5. Production sub-units 201, 202, 203 and 204 areintegrated into the upper Conex container 214, with 205, 206 and 207situated in the lower Conex container. The number of productionsub-units per Conex container can be reconfigured without limitation.Also illustrated in FIG. 5 is the configuration of production sub-unitsub-frame. Shown is the wall 208, base and a raised center-point 212.

The Conex structures have structural rigidity, have four self-supportingwalls and are linear such as to form a rectangular box. Structuralrigidity is conferred by a steel frame and welded steel walls ofcorrugated steel. Structural rigidity is of paramount importance becausethe base Conex must support one or more identical size structures placeddirectly on top. In addition, each Conex should be able to retainstructural integrity when the production sub-units 201-207 are filledwith water and weight is transferred to the Conex walls and downward tocorner supports. There cannot be any dimensional change, along the x-,y- or z-axis or it will result in elevation differences that will causewater depth changes in the production sub-units and shrimp productionissues.

Configuration of a production module is illustrated further in FIG. 6.Shown in FIG. 6 is a schematic of a partial see through side view of twostacked Conex inter-modal containers (712, 713) in which productionsub-units arranged vertically in each (701, 702, 703, 704, 705, 706,707). A harvest pit 711 is shown as being located at the left end ofeach production sub-unit. Also illustrated are access door panelsinstalled just above the water level of production sub-units 702, 703,704, 705, 706 and 707. These doors have gaskets and a lockingarrangement such that they completely form a tight seal when closed. Thedoors are purposely situated to allow monitoring of shrimp andconditions associated with production sub-units, e.g., feeddistribution, water circulation, aeration, etc. There is limitedvertical space between the production sub-units 701 and the roof of 712.As noted previously, the number of production sub-units per Conex isflexible and can be varied. Otherwise all production sub-units areidentical in design.

All production sub-units have the same design and are fabricatedexternally as a unit, before being inserted into a Conex. There is noelevation difference along the length of each raceway. Water depth ineach production sub-unit is set at an average depth of 35 or more cm.One such production sub-unit configuration is shown in FIG. 7A. Eachproduction sub-unit is ˜2.4 meters wide by 15.5 meters long. A structurefor inclusive purposes termed a pit 412 (FIGS. 7 A, B and C) isconstructed at one end and an end cap structure constructed at theopposite end (FIG. 7A). It is designed to facilitate waterrecirculation.

A description of the production sub-unit module in FIG. 7A comprises arectangular cuboid tank having a raised lengthwise depth-line that ismore shallow in middle of the tank (see cross section FIGS. 8A and 8B)with a pit structure (FIGS. 7B and 7C) located at the first end of thetank and cap structure located at the second end of the tank. Therectangular cuboid tank is capable of holding fresh or salt water. There-circulating aquatic system is in fluid communication with theproduction sub-unit module. Additionally, the feed distribution moduleis in fluid communication with the production sub-unit module. Thecomputer control module is interfaced with one or more equipment modulesconnected to the production sub-unit module, the re-circulatingaquaculture system module and/or the feed distribution module.

According to a more specific embodiment the pit comprised of multiplesub-structures 406, 408 (FIGS. 7B and C) is 25 to 35 cm in depth asmeasured from the bottom 402 of FIG. 7B and 402 404 of FIG. 7C to thebase 408. The pit length 404 (FIG. 7C) is 1.2 meters long. The sidewalls 402 and 404 (FIGS. 7 A, B and C) that extend all around theproduction sub-unit are 40 cm in height. The side walls of the pit arecontiguous with the walls of the rest of the production sub-unit. Whenthe container doors are closed, each production sub-unit forms anisolated enclosed compartment relative to those positioned above andbelow. The end sidewalls 412 and 417 are angled outward 5-15 degrees atthe corners to facilitate water circulation and eliminate blind spotdetritus accumulation.

The pit structure 412 (FIGS. 7A, B and C) has many functions necessaryfor a multi-phasic integrated super-intensive production system to work.From a functional perspective, four physical openings were designed intothe bottom of the pit 409, 410, 411 and 413 (FIG. 7A). Water that iscirculated in a counter-clockwise direction by directional nozzles (seebelow), when passing over and interacting with water in the pit 412 willslow down. Waste present in the water will sediment out, accumulating onthe bottom 408 (FIG. 7B). For removal purposes, detritus includingshrimp fecal material is gently suspended by sending water through acapped directional nozzle 409 (FIG. 7A) and captured by screen cappedoutlets 411 and 413. The screened outlets 411, 413 are permeable towaste. Screens are sized as to retain shrimp. Water and detritus passingthrough the screen caps is pumped to the Recycling Aquaculture System(RAS), See RAS Module below (FIG. 9). Also located within the pit, i.e.,at the bottom, is an outlet 410 (FIGS. 7A and 7C). This outlet is usedfor shrimp transfer and harvesting. For the purposes described, a largediameter flex-tube can be connected to 410 and when a gate valve isopened, water along with shrimp will pass through the opening. Water andshrimp can thereby be diverted to a lower tier production sub-unit orsent to harvest tank. In either case it is often desirable to quantitatethe number of shrimp being transferred or harvested. This can beaccomplished by attaching a flex tube to a Larcos Shrimp Counter(Flanery, W., Kramer, K., Steimle, E., and Kristjansson, H., “BriefDescription of the Larcose Shrimp Counter,” VAKI Aquaculture SystemsLtd., Web, 21 Feb. 2013) and allowing the shrimp suspended in water topass through a photo-electric sensor connected to a computer, whereincomputer imaging software is used to process the image and count thenumber of shrimp. For example, a Larcose shrimp counter is a video-basedcounting system that uses computer-imaging-recognition to count postlarvae. It can recognize any object from about 3 mm to 200 mm. It cancount post larvae as small as PL-5's, even differentiates the live onesfrom the dead ones. Using a flow through counting system does away withnets, water chilling and statistical guesswork.

In the case of partial transfer, real time counting allows operator toquantitate and disburse shrimp into production sub-units as desired. Itdoes away with nets and/or statistical guesswork. Use of the counteralso has application if the shrimp are to be offered for sale as liveshrimp, i.e., it allows an operator to enumerate the number of shrimpconsigned to a client at the point of sale.

Water level in a production sub-unit is maintained by a stand pipe and adepth sensor. On demand water depth is restored by water pumped intoeach production sub-unit from a storage tank that is part of RAS. Watercirculation around the production sub-unit is driven by recycled waterpumped into the production sub-unit from RAS and air dispersion nozzleslocated around the side walls of the linear lengths of the productionsub-units.

Disclosed in FIGS. 7 A, B and C is the overall design of the productionsub-unit. For fabrication purposes a wire frame sub-structure comprisedof heavy gauge stainless steel wire mesh is constructed. It is shaped toform the base 604 (FIG. 8A) and sidewalls 602 (FIGS. 8A and B) of theproduction sub-unit. To complete construction of the production sub-unita 100 mil high density polyethylene (HDPE) liner is fitted over thesub-frame and where required joints are heat welded to form a watertight compartment.

The sub-structure and liner that constitute a production sub-unit aresupported at linear intervals by cross braces 603 (FIG. 8B). Cutouts inthe cross-braces 605 (FIG. 8A) are situated to facilitate plumbing andwiring installation necessary for operation. Example, when transferringor harvesting shrimp, high water pressure lines routed through the crossbrace cutouts 605 that are to computer controlled actuator valves can beactivated. Water in a successive pulse sequence starting from therecirculation end cap moving towards the harvest pit 412 (FIG. 7A) canbe used to clear any shrimp from the production sub-units. This is anecessary step because although they may be flushed out of theproduction sub-unit with evacuated water, a certain percentage arepredisposed to become stranded in an attempt to counter the water flow.

The production sub-unit bed 604 is fabricated such that it is flat 30 cmlaterally from the sidewall 602 (FIG. 8A), then pitches upward to thecenter and down to the opposing sidewall. Thus it forms an arch likestructure having an center elevation ˜20 cm directly above the centerpoint of the support brace 603 (FIG. 8B). From a functional perspective,the elevated center aids in water circulation along the linear axis ofthe production sub-unit as well as aeration, detritus removal, formationof increased surface area and facilitates harvesting of shrimp bycreating a deep water drainage channel on either side of the productionsub-unit.

Also shown in FIGS. 8 A and B, are brackets 601 located at the end ofeach support brace 603 (FIG. 8B). When the production sub-unit isinstalled in the Conex, the brackets are welded to walls and are themeans of support for the fully assembled production sub-unit.

Each production sub-unit in the production module is independentlyconnected to a closed loop water recycling aquaculture system (RAS)module. A flow diagram of the RAS module is shown in FIG. 9. RASprocessed water before being cycled back to individual productionsub-units is heated to (31-33° C.) using a heat exchanger. Likewise,compressed air is pre-conditioned prior to being injected throughconnection ports in side of the production module (Conex wall) and theside walls of the production sub-units. The amount of air injectedthrough diffusers will be controlled by flow valves and pressureregulators that can be computer controlled.

Aeration is a critical requisite in shrimp aquaculture. Ambient air mayvary significantly through the day outside the production module. Coldair when used for aeration can dramatically decrease water temperature,reduce shrimp metabolism, i.e., shrimp growth, and drive up the energycosts of production. Therefore, tempered compressed air will be used tooxygenate the water in each production sub-unit.

Additional monitoring features are embodied in the design of theproduction module. When in operation everything inside the productionmodule is isolated from ambient outside environment. Therefore, a methodhad to be devised to monitor activities within the tunnel like spaceabove production sub-units installed within the Conex container duringgrow out. This being the objective, LED's are located on the walls abovethe water line of each production sub-unit and a Charge Coupled TV(CCTV) camera is strategically placed above each production sub-unit.The signal from each CCTV camera is fed back to a central work stationwhere it can be monitored. Illumination during grow-out is kept at a lowintensity. It is raised infrequently to a level sufficient for thepurpose of checking to determine if there are issues with circulation,feed disbursement and consumption or the shrimp themselves.

A cyber-physical system (“CPS”) is a system of collaboratingcomputational elements controlling physical entities. Unlike moretraditional embedded systems, a full-fledged CPS is typically designedas a network of interacting elements with physical input and outputinstead of as standalone devices. The notion is closely tied to conceptsof robotics and sensor networks with intelligence mechanisms proper ofcomputational intelligence leading the pathway. Ongoing advances inscience and engineering will improve the link between computational andphysical elements by means of intelligent mechanisms, dramaticallyincreasing the adaptability, autonomy, efficiency, functionality,reliability, safety, and usability of cyber-physical systems that iswithin the spirit and scope of the invention disclosed within. Forexample, other monitoring equipment included water quality sensorsembedded in each production sub-unit. Data from the sensors connectedvia a cyber-physical platform will be feedback in real time to a centralcomputer. Physical and chemical measurements to be monitored include:water temperature, salinity, dissolved oxygen, pH, total dissolved solid(TDS), nitrogen metabolite levels (ammonia, nitrites, nitrates) as wellas acoustics (feeding activity).

Re-Circulating Aquaculture System (RAS) Module

According to a specific embodiment described herein stacked productionsub-units within the shrimp grow-out production module should beoperated using closed loop RAS. Illustrated in FIG. 9 is a RAS designedto operate in conjunction with the integrated multi-phasic shrimpproduction system. Briefly, as shown in FIG. 9, influent filterednatural seawater 102 or well water 104 is combined with sea salt 108 toa desired salinity before being placed into a storage reservoir 109. Thesalt water is then distributed to the production sub-units 110, 112,114, 116, 118, 120 and 122 constructed in a production module by pumps.Water pumped directly to each production sub-unit is not aerated. It isprovided separately to each production sub-unit 111, 113, 115, 117, 119,121 and 123.

Closing the loop, water from each production sub-unit 110, 112, 114,116, 118, 120 and 122, in which shrimp are grown is removed at acontrolled rate and sent to a Micro-screen Drum Filter 126 to removedetritus (excess feed, feces, etc.) before being pumped to Moving BedBio-Reactor (MBBR) 124 for reprocessing to remove suspended waste, inparticular ammonia. The water pumped to the MBBR 124 is cascadeddownward through a cross jet of natural air to remove carbon dioxide. Itthen passes over a micro-bead media to denitrify the water. Ammonia isconverted to nitrate by bacteria attached to the media. Water from theMBBR 124 is cycled through a foam fractionator 125 to remove emulsifiedproteinaceous materials and returned to the MBBR. Water tempered is thenreturned to each production sub-unit (110, 112, 114, 116, 118, 120 and122) by pumps 130. Water saturated waste from 124 and 125 is diverted to127 an Up-flow Anaerobic Sludge Blanket Reactor 127 for processing.Sludge from 127 is removed as needed and used as high nitrogenfertilizer or sent to a landfill. Water is placed in storage 128 forrecycling back into the operation.

Feed Distribution Module

Shrimp will consume feed 24/7, thus a system to accomplish this wasdevised in order to maximize shrimp production. There are severalproblems associated with non-floating shrimp feed. For example, feedspread across the water surface or by injection at a single point israpidly hydrated on contact. The water quickly leaches away nutrientsand/or chemotractants. Thus, not only is the non-floating shrimp feedless nutritious, over time the shrimp cannot even detect it. Feedbecomes nutritive source for bacteria resulting elevated ammoniaproduction. It is also difficult to judge whether the shrimp have eatenall of such feed because it cannot be seen through the water. As aresult, shrimp may easily be fed too much feed, leading to waste andwater pollution, or too little feed, resulting in less rapid growth.Non-optimal feeding may also occur because non-floating shrimp feedshould be spread over the surface of the water by the feeding system;otherwise it will simply sink in one area and not provide feed equallyto shrimp in all areas. While access to a production module is providedby access panels inserted above the production sub-units (see FIG. 6),it is inconceivable that panels could be opened on a routine basismultiple times per day to distribute feed and/or mechanical system couldaccomplish this without driving the cost up very substantially. Overall,new systems and methods of shrimp aquaculture are needed to address oneor more of the above problems as well as other difficulties.

For purposes of the embodiment described herein a floating feed wasselected. Floating feed prepared by a preconditioning and extrusioncooking process that pasteurizes the product is preferred, as thistechnology lends itself to making small diameter feeds that are stable.As described in United States Patent Application Publication US2012/0204801, use of a floating feed facilitates: feeding shrimp using amechanical point feeding system, feeding shrimp whenever needed 24 hoursa day, decreasing water pollution and waste due to unconsumed feed,optimizing feed rate by observing when feed has been consumed,increasing shrimp growth rate, decreasing shrimp death rate, improvingoverall shrimp health, decreasing nutrient leaching from the feed,decreasing feed loss with the discharge (removal of water) from theproduction system, and reducing the amount of feed required to produce apound of shrimp, i.e., reducing the FCR (Feed Conversion Ratio).

A multi-phasic shrimp production system presents a unique problem, i.e.,a one size feed does not fit all. Small shrimp at Phase 2 of grow out(see Table 1) are not able to efficiently consume feed pellets that aresuitable for shrimp at Phase 4 of grow-out (see Table 1). Therefore, asystem was devised that could provide size appropriate feed on areal-time basis to each production sub-unit wherein shrimp ranging insize from 0.7-30 plus grams may be present.

In addition to feed considerations, environmental factors have to beaddressed when designing a feed distribution system. The environmentwithin the grow-out production-module as a whole, but more importantlyin the volume occupied by each production sub-unit, is highly watersaturated. Feed pellets, including floating feed pellets willagglomerate to wall of any tube through which feed is introduced bygravity and/or through an air driven distribution system. Therefore, afeed distribution system modified from that of a system originallydesigned by Environmental Technologies Inc. was integrated into themulti-phasic production system disclosed herein to deal with associatedissues.

To address issues described above, an on demand feed distribution systemwas devised to distribute four different size feeds. In addition,environmental factors were eliminated by hydrating the feed and pumpingit directly to each production sub-unit through feed-tubes. Thedistribution system is shown in FIG. 10. The system is designed aroundthe objective of selectively dispensing four different sized feeds fromstorage hoppers to production sub-units 310, 312, 314 and 316. Switchingsources is by computer controlled actuators.

Briefly, selected feed is augured by computer controlled drives fromfeed silos 307 (FIG. 10) via a screw auger 320 to a hydration tank 322.In rapid succession water is pumped 321 into the hydration tank 322 andthe suspended feed is immediately pumped 326 to a manifold 324. Thesuspended feed now present in the manifold 324 is then distributed bypumps to the desired production sub-unit, i.e., 310, 312, 314, or 316,through water charged distribution tubes 306 when computer controlledactuator valves at the manifold 324 are opened. After discharge,pressurized water from 323 is flushed through an actuator control valve325 into the manifold 324 and then through the distribution tubes 306 topurge any residuals in system before next feeding cycle is activated.Flushing will prevent feed accumulation, leaching of the feed, etc. Eachfeeding tube is ported through the wall of each container into a feedingpoint above the water level of each production sub-unit allowing forsingle-point feeding. Along with the feed distribution system, aeratorsfor production sub-units 311, 313, 315 and 317 are indicated (FIG. 10).

Example 1

A preferred modularized shrimp production system comprises several unitsincluding:

a. a post-larvae nursery module;

b. a production sub-unit module;

c. a re-circulating aquaculture system (RAS) module;

d. a feed distribution module; and

e. a computer control module,

The basic operations of the system are modularized and integrated toform a multi-phasic synchronous super-intensive shrimp production systemcontrolled by a custom designed cyber-physical platform that acquiresdata through sensors embedded in post-larvae nursery module, productionsub-unit module, re-circulating aquaculture system (RAS) module, andfeed distribution module that allows regulation of all aspects byProgram Logic Controllers (PLCs) integrated with Human Interface Modules(HIMs) through coupled feed-back loops for maintaining an aquacultureenvironment for a synchronous production cycle of shrimp. The preferredpost-larvae nursery module includes at least one shallow-water-tank forproducing juvenile shrimp. The post-larvae nursery module is in fluidconnection with the post-larvae re-circulating water system (“PLRAS”)module, the feed distribution module, and the computer control module.The post-larvae nursery module has all equipment to be a stand aloneunit, but some aspects can be integrated into the entire productionssystem. The production sub-unit module comprises at least onerectangular-cuboid-tank having a raised lengthwise depth-line that isshallower in middle of the tank with a harvest pit structure located atone end of the tank and a cap structure located at an other end of thetank. This rectangular cuboid tank is capable of holding water andfitted with at least one valve for introducing and evacuating water. There-circulating aquatic system (RAS) is in fluid communication with theproduction sub-unit module. The feed distribution module is in fluidcommunication with the production sub-unit module. The computer controlmodule is in electrical communication with human interface modules(“HIMs”). In a preferred embodiment, one or more equipment devices thatare linked to the post-larvae nursery module, the production sub-unitmodule, the re-circulating aquaculture system module or the feeddistribution module.

The post-larvae nursery module comprise one or more shallow water tankshaving the dimensions of about 8 ft by about 8 ft by about 1.5 ft thatare sloped at an angle of about 0.5-1.5% toward a stand-pipe situated ina corner of the tank. The water depth in shallow-water-tank ismaintained at an average depth in the range of 30-50 cm, and preferablyabout 40 cm. The dimensions of the preferred production sub-unit modulecomprises one or more rectangular-cuboid-tank having the dimensions ofabout 7.9 ft×about 52 ft×about 1.55 ft including the harvest pit at oneend and a recirculation end cap at the other end. Each of theserectangular-cuboid-tanks are stacked inside a first conex containerhaving dimensions of about 8 ft by about 53 ft by about 9.6 ft. There-circulating aquaculture system (RAS) module is made up of pumps,connections and valves forming independently connected closed looprecirculation from the RAS module to each production sub-unit module'srectangular-cuboid-tank contained inside the first conex container. In apreferred embodiment, the re-circulating aquaculture system (RAS) iscontained within a second conex container.

The preferred modularized shrimp production system contains certainequipment and/or devices for monitoring, maintaining or altering themodularized shrimp production system. For example, such equipment mayhave a Program Logic Controller (PLC) for controlling a specific lightlevel; a water circulation rate; a tank water level; a water temperaturein a range of 29-33° C.; a pH concentration; a salinity concentration inthe range of 10-14 parts per thousand; a dissolved oxygen level in arange greater than 4.5 mg/L; a nitrogen metabolite concentration; asensor to detect the modulation of surface acoustic waves to sense aphysical phenomenon; a total dissolved solids index; a visual eventoccurring in the tank; a live or a recorded visual event in the tank; orcombination thereof.

In a preferred embodiment, the components for monitoring, maintaining oraltering the aquaculture environment for a synchronous production cycleof shrimp rely on the Program Logic Controller (PLC), which isessentially an industrial computer that controls different components orprocesses of the modularized shrimp production system and is programmedaccording to the operational requirements of the system. Numerousoff-the-shelf and/or custom systems are available from Siemens, AllenBradley (Rockwell) or numerous other custom PLC systems available fromother vendors.

The preferred components for monitoring, maintaining or altering thespecific light level comprises light emitting diodes (LED's) mountedabove the waterline of each production sub-unit are known in the artbecause LED's have been on the market for many years. The components formonitoring, maintaining or altering the water circulation rate comprisepumps and valves are also available from numerous commercialmanufactures. The components for monitoring, maintaining or altering thetank water level comprise liquid level sensors. The components formonitoring, maintaining or altering the water temperature comprisescompressed air being pre-conditioned to 31° C. by passage through a heatexchanger before being disbursed into the water through micro-dispersionnozzles. The components for monitoring, maintaining or altering the pHconcentration comprises a pH probe. The components for monitoring,maintaining or altering the salinity concentration in the range of 10-14parts per thousand comprises conductivity sensors that measure water'scapability to pass electrical flow and alert a user or make adjustmentsdirectly. The components for monitoring, maintaining or altering thedissolved oxygen level in a range greater than 4.5 mg/L comprises adissolved oxygen sensors of the polarographic, rapid-pulsing, galvanicand optical type. The components for monitoring, maintaining or alteringthe nitrogen metabolite concentration comprise sensors that alert auser. Manufacturers of many sensors mentioned above include YSI byXylem, Pentair Aquatic, Campbell Scientific, AQ1, Ametek, and Hach.

Preferred component for monitoring, maintaining or altering the sensorto detect the modulation of surface acoustic waves to sense a physicalphenomenon comprises acoustic feeding sensors such as ones from AQ1Systems. More specifically, the SF200 Sound Feeding System for Shrimp isthe world's first sensor based feeding control system for shrimpfarmers. The system uses passive acoustics to identify shrimp feedingactivity and then uses that information to control temporal feeddelivery via an adaptive feeding algorithm. The adaptive algorithmensures feed delivered matches shrimp appetite so that all animals arefed fully without waste 24 hours a day if required.

Moreover, the preferred components for monitoring, maintaining oraltering the live or the recorded visual event occurring in the tankcomprises a Charge Coupled TV (“CCTV”) camera connected. One preferredmodel includes the infrared CCTV Model: Water Proof BW® 700TVL sold bythe BW Group, China. Other models include the Hikvision DS-2CD2012-I-4MM1.3 MP Outdoor Bullet IP Camera from Hikivision USA, City of Industry,Calif.

Another preferred embodiment of the modularized shrimp production systemincludes a high pressure water line with a computer controlled actuatorvalve routed above each production sub-unit. Using this configuration,high pressure water can be released into each production sub-unit inpulses starting from the recirculation end cap and forcing the shrimp tomove towards the harvest pit to facilitate harvesting of shrimp.

The preferred re-circulating aquaculture system (RAS) described aboveincludes a storage reservoir tank in fluid connection with a closed loopsystem. The closed loop system includes a Moving Bed Bio-Reactor (MBBR)in fluid connection with a pump. The preferred pump is in fluidconnection with the production sub-unit. The preferred productionsubunit is in fluid connection with a Micro-Screen Drum Filter used toremove detritus. The preferred Micro-Screen Drum Filter is in fluidconnection with the MBBR and an Up-flow Anaerobic Sludge BlanketReactor. The preferred MMBR has a fluid connection to a foamfractionator used to remove emulsified proteinaceous materials from thewater and returned the water to the MBBR. The preferred foamfractionator has a fluid connection to the Up-flow Anaerobic SludgeBlanket Reactor that is used for processing and removing sludge to beused as high nitrogen fertilizer or landfill. The preferred up-flowAnaerobic Sludge Blanket Reactor is in fluid connection with a recycledwater storage tank. The preferred storage reservoir tank is in fluidcommunication with a filtered natural seawater tank or a well water tankthat is in fluid connection with a mixing tank used for mixing water andsea salt to a desired salinity to be transferred to the storagereservoir tank.

The shallow water tanks and rectangular-cuboid-tanks can be fabricatedfrom materials including: fiberglass, wood composites, syntheticplastics, polyethylene, propylene, acrylonitrile butadiene, styrene,epoxy coated steel, metals, or combination thereof. However, otherbuilding materials that are known in the art may also be utilized fortank production and would be considered within the spirit and scope ofthe invention. Each of the rectangular-cuboid-tanks can be constructedwith multiple ports that are inserted through the tank walls to allowfor placement of micro-dispersion nozzles for aeration, directionalnozzles through which water reprocessed using the recycling aquaculturesystem (RAS) that can be pumped to circulate water in any direction buta preferred counter-clockwise direction in each tank. Additionally, thepreferred harvest pit for each rectangular-cuboid-tanks is constructedwith outlets for collection and removal of detritus as well asharvesting of shrimp. The preferred shallow water tanks andrectangular-cuboid-tanks have been designed with certain dimensions sothey can be placed inside an inter-modal container.

Example 2

A second embodiment of the current invention includes a method forhaving a synchronous production cycle of mature shrimp using amodularized shrimp production system. The preferred method comprises:

-   -   a. preparing an aquaculture environment for a synchronous        production cycle of shrimp;    -   b. stocking post larvae shrimp in a post-larvae nursery module;    -   c. raising post larvae shrimp to a juvenile stage shrimp in the        post-larvae nursery module to a desired size, forming a        first-phase-shrimp population;    -   d. transferring the first-phase-shrimp to a production sub-unit        rectangular-cuboid-tank;    -   e. growing the juvenile stage shrimp in the production sub-unit        rectangular-cuboid-tank for a first period of time (i.e. until        the shrimp reach a desired size), forming a second phase-shrimp        population;    -   f. dividing the second-phase shrimp population into two separate        production sub-unit rectangular-cuboid-tanks;    -   g. growing the second-phase-shrimp population in each of the two        separate production sub-unit rectangular-cuboid-tanks for a        second period of time (i.e. until the shrimp reach a desired        size) forming a third-phase-shrimp population;    -   h. harvesting a portion of the third-phase shrimp population;    -   i. dividing the third-phase shrimp population into two separate        production sub-unit rectangular-cuboid-tanks;    -   j. growing the third-phase-shrimp population in each of the two        separate production sub-unit rectangular-cuboid-tanks for a        third period of time (i.e. until the shrimp reach a desired        size) forming a fourth-phase-shrimp population;    -   k. harvesting of the fourth-phase shrimp population.

The preferred embodiment establishes a synchronous production cycle byrepeating steps (a) through (k) and assuring that the productionsub-unit rectangular-cuboid-tanks of the modularized shrimp productionsystem are restocked as soon as they are emptied by the respectivedividing of different shrimp populations. Additionally, the steps couldbe continued for a fifth-phase shrimp population or beyond. An extensionof the number of phases possible with the modularized shrimp productionsystem would depend on the scale of production needed. However, if themodules could be increased, the number of x-phase shrimp populationscould be extended and would be considered within the spirit and scope ofthis invention.

The preferred invention understands that all shrimp growth phases andbasic operations are modularized and integrated to form a multi-phasicsynchronous super-intensive shrimp production system controlled by acustom designed cyber-physical platform that acquires data throughsensors embedded in post-larvae nursery module(s), production sub-unitmodule(s) (i.e. same as grow-out production module), recirculatingaquaculture system (RAS) module(s), and feed distribution module(s) thatallows regulation of all aspects by Program Logic Controllers (PLCs)integrated with Human Interface Modules (HIMs) through coupled feed-backloops. The preferred shrimp growing conditions include having theoptimal conditions for lighting, feeding, water temperature, waterlevel, water pH and water saline concentrations that are conducive foroptimal and efficient shrimp maturation. Because the modularizedaquaculture system allows shrimp to be farmed in any climate, it isunderstood by one having ordinary skill in the art that some of theseparameters may need to be optimized based on geography (i.e. humidity,elevation, temperature, etc). The preferred post-larvae nursery modulehas at least one shallow-water-tank for producing juvenile shrimp,wherein the post-larvae nursery module is in fluid connection apost-larvae re-circulating water system (“PLRAS”) module, a feeddistribution module, and a computer control module.

The preferred rectangular-cuboid-tank has a raised lengthwise depth-linethat is shallower in middle of the tank when filled with water. Theharvest pit structure is located at one end of the tank and a capstructure is located at the other end of the tank. The preferredrectangular cuboid tank of the production sub-unit module is capable ofholding water and fitted with at least one valve for introducing andevacuating water. The preferred re-circulating aquatic system is influid communication with the post-larvae nursery module and theproduction sub-unit module; wherein the feed distribution module is influid communication with each production sub-unit in a productionmodule. The preferred computer control module is interfaced with humaninterface modules (“HIMs”) and one or more equipment devices that areconnected to the post-larvae nursery module, the production sub-unitmodule, the re-circulating aquaculture system module or the feeddistribution module.

A preferred method includes stocking post larvae shrimp at a density of4,000-8,000/m² into each vertically stacked shallow water tanksinstalled in the nursery module. Additionally, the preferred aquacultureenvironment for a synchronous production cycle of shrimp is preserved bymonitoring, maintaining or altering: a specific light level; a watercirculation rate; the shallow-water-tank water level the range of 30-50cm; the shallow-water-tank water level above 35 cm; a water temperaturein a range of 29-33° C.; a pH concentration; a salinity concentration inthe range of 10-14 parts per thousand; a dissolved oxygen level in arange greater than 4.5 mg/L; a nitrogen metabolite concentration; asensor to detect the modulation of surface acoustic waves to sense aphysical phenomenon; a total dissolved solids index; a visual eventoccurring in the tank; a live or a recorded visual event in the tank; orcombination thereof. A more preferred method for preparing theaquaculture environment is by using compressed air that ispre-conditioned to 31° C. by passage through a heat exchanger in thenursery module before being disbursed into nursery tank water throughmicro-dispersion nozzles.

Moreover, preparing and maintaining the aquaculture environment is aidedby embedding each production sub-unit with sensors for watertemperature, water level, salinity, dissolved oxygen, pH, totaldissolved solid (TDS), nitrogen metabolite levels (ammonia, nitrites,nitrates) as well as acoustics (feeding activity). In short, most if notall physical and chemical measurement data are connected via acyber-physical platform through a Program Logic Controller (PLC)integrated with Human Interface Modules (HIMs) for real-time feedbackand adjustments.

Preparing the aquaculture environment includes using a computercontrolled feed distribution system that draws feed from one of four ormore different feeds from attached hoppers. The dry feed is thenhydrated and dispensed to a targeted production sub-unit based onsignals from the Program Logic Controller (PLC).

Another method of preparing the aquaculture environment includesembedding in each production sub-unit with sensors for monitoring,maintaining or altering the modularized shrimp production system using aProgram Logic Controller (PLC) for controlling different components orprocesses of the modularized shrimp production system, wherein the PLCis programmed according to the operational requirements of the system.The preferred components for monitoring, maintaining or altering thespecific light level comprises light emitting diodes (LED's) mountedabove the waterline of each production sub-unit. The preferredcomponents for monitoring, maintaining or altering the water circulationrate comprise pumps and valves. The preferred components for monitoring,maintaining or altering the tank water level comprise liquid levelsensors. The preferred components for monitoring, maintaining oraltering the water temperature comprises compressed air beingpre-conditioned to 31° C. by passage through a heat exchanger beforebeing disbursed into the water through micro-dispersion nozzles. Thepreferred components for monitoring, maintaining or altering the pHconcentration include a pH probe or other means for measuring pH. Thepreferred components for monitoring, maintaining or altering thesalinity concentration in the range of 10-14 parts per thousand includeconductivity sensors that measure water's capability to pass electricalflow and alert a user or make adjustments directly. The preferredcomponents for the components for monitoring, maintaining or alteringthe dissolved oxygen level in a range greater than 4.5 mg/L comprises adissolved oxygen sensors of the polarographic, rapid-pulsing, galvanicand optical type; the components for monitoring, maintaining or alteringthe nitrogen metabolite concentration comprises sensors that alert auser; the component for monitoring, maintaining or altering the sensorto detect the modulation of surface acoustic waves to sense a physicalphenomenon comprises; the components for monitoring, maintaining oraltering the total dissolved solids index comprises sensors that alert auser; the components for monitoring, maintaining or altering the live orthe recorded visual event occurring in the tank comprises a ChargeCoupled TV (“CCTV”) camera connected.

A preferred method of harvesting shrimp involves using high pressurewater lines routed above each production sub-unit and connected tocomputer controlled actuator valves activated in pulses starting fromthe recirculation end cap moving towards the harvest pit.

Although only exemplary embodiments of the invention are specificallydescribed above, it will be appreciated that modifications andvariations of these examples are possible without departing from thespirit and intended scope of the invention. For example, one of ordinaryskill in the art will appreciate that measurements, particularly ofraceway dimensions, shrimp weight and time are approximate and may bevaried to some degree without departing from the spirit and scope of theinvention. One of ordinary skill in the art will also appreciate that inmost instances, the weight of the water contained accounts for most ofthe production sub-unit weight. Accordingly, it may be possible tovertically arrange production sub-units having walls higher thandescribed herein, but in which water depth is nevertheless around therecited wall heights. The sides of the container in which the productionsub-units are installed effectively become an extension of theproduction sub-unit sides.

One of ordinary skill in the art will appreciate that productionassemblies and production sub-units fabricated herein can be of variousmeasurements. Inter-modal containers are generally available in lengthsof 20 ft (6.1 m), 40 ft (12.2 m), 45 ft (13.7 m) and 53 ft (16.5 m)lengths and are produced having variable heights. It is also possible tolink containers in multiple iterations and fabricate productionsub-units inside so as to create increased shrimp production. Withoutlimitation it is conceivable that container like rigid structures can beconstructed having width, length and height different from generallyavailable containers. Such structures again would open the possibilityof significantly increasing shrimp production. A structure so describedmay in fact be a freestanding building connected to Nursery, RAS andFeed Modules along with a computer activated controls. Production modelslike the modules described herein, are exemplary and revising thesemodules to meet market demands are considered to be within the sprit andscope of the invention.

What is claimed is:
 1. A modularized shrimp production system,comprising: a. a production sub-unit module; b. a re-circulatingaquaculture system (RAS) module; c. a feed distribution module; and d. acomputer control module, wherein, basic operations of shrimp productionare modularized and integrated to form a multi-phasic synchronoussuper-intensive shrimp production system controlled by a custom designedcyber-physical platform that acquires data through sensors embedded inthe production sub-unit module, recirculating aquaculture system (RAS)module, and feed distribution module, allowing control of one or moreequipment devices communicating with the Program Logic Controllers(PLCs) integrated with Human Interface Modules (HIMs) through coupledfeed-back loops for maintaining an aquaculture environment for asynchronous production cycle of shrimp; wherein the production sub-unitmodule comprises at least one rectangular-cuboid-tank having a raisedlengthwise depth-line that is more shallow in middle of the tank with aharvest pit structure located at one end of the tank and a cap structurelocated at an other end of the tank; the rectangular cuboid tank iscapable of holding water and fitted with at least one valve forintroducing and evacuating water; wherein, the re-circulating aquaticsystem is in fluid communication with the production sub-unit module;wherein the feed distribution module is in fluid communication with theproduction sub-unit module; and wherein the computer control module isin electrical communication with human interface modules (“HIMs”) andone or more equipment devices that are linked to the post-larvae nurserymodule, the production sub-unit module, the re-circulating aquaculturesystem module or the feed distribution module.
 2. The modularized shrimpproduction system of claim 1, further comprising: a post-larvae nurserymodule; a post-larvae-re-circulating-aquaculture-system (PLRAS) module;wherein, basic operations of the post-larvae nursery module areintegrated into the multi-phasic synchronous super-intensive shrimpproduction system controlled by a custom designed cyber-physicalplatform that acquires data through sensors embedded in post-larvaenursery module with the post-larvae-re-circulating-aquaculture-system(PLRAS) module allowing control of one or more equipment devicescommunicating with the Program Logic Controllers (PLCs) integrated withthe Human Interface Modules (HIMs) through coupled feed-back loops formaintaining an aquaculture environment for a synchronous productioncycle of post-larvae shrimp; wherein, the post-larvae nursery modulehaving at least one shallow-water-tank for producing juvenile shrimp,the post-larvae nursery module is in fluid communication with thepost-larvae-re-circulating-aquaculture-system (“PLRAS”) module, the feeddistribution module, and the computer control module.
 3. The modularizedshrimp production system of claim 2, wherein the post-larvae nurserymodule comprise one or more shallow water tanks having the dimensions ofabout 8 ft by about 8 ft by about 1.5 ft that are sloped at an angle ofabout 0.5-1.5% toward a stand-pipe situated in a corner of the tank;wherein one or more shallow-water-tank are stacked inside apost-larvae-nursery-conex container; wherein water depth inshallow-water-tank is maintained at an average depth in the range of30-50 cm, and preferably about 40 cm; wherein the water depth in eachshallow-water-tank is independently maintained using a stand-pipeplumbed through the wall of the post-larvae-nursery-conex container intothe equipment compartment; wherein a diverter valve and a pump maintainwater levels by circulation from a storage tank.
 4. The modularizedshrimp production system of claim 1, wherein the production sub-unitmodule comprises one or more rectangular-cuboid-tank having thedimensions of about 7.9 ft×about 52 ft×about 1.55 ft including theharvest pit at one end and a recirculation end cap at the other end,wherein each rectangular-cuboid-tank are stacked inside a first conexcontainer having dimensions of about 8 ft by about 53 ft by about 9.6ft; wherein the re-circulating aquaculture system (RAS) module furthercomprises pumps, connections and valves forming independently connectedclosed loop recirculation from the RAS module to each productionsub-unit module's rectangular-cuboid-tank contained inside the firstconex container; wherein the re-circulating aquaculture system (RAS) iscontained within a second conex container.
 5. The modularized shrimpproduction system of claim 1, wherein the equipment devices furthercomprising components for monitoring, maintaining or altering themodularized shrimp production system comprising: a Program LogicController (PLC), a specific light level; a water circulation rate; theproduction sub-unit rectangular-cuboid-tank water level above 35 cm; awater temperature in a range of 29-33° C.; a pH concentration; asalinity concentration in the range of 10-14 parts per thousand; adissolved oxygen level in a range greater than 4.5 mg/L; a nitrogenmetabolite concentration; a sensor to detect the modulation of surfaceacoustic waves to sense a physical phenomenon; a total dissolved solidsindex; a visual event occurring in the tank; a live or a recorded visualevent in the tank; or combination thereof.
 6. The modularized shrimpproduction system of claim 5, wherein the components for monitoring,maintaining or altering the aquaculture environment for a synchronousproduction cycle of shrimp, wherein, the Program Logic Controller (PLC)comprises an industrial computer that controls different components orprocesses of the modularized shrimp production system and is programmedaccording to the operational requirements of the system; the componentsfor monitoring, maintaining or altering the specific light levelcomprises light emitting diodes (LED's) mounted above the waterline ofeach production sub-unit; the components for monitoring, maintaining oraltering the water circulation rate comprise pumps and valves; thecomponents for monitoring, maintaining or altering the tank water levelcomprise liquid level sensors; the components for monitoring,maintaining or altering the water temperature comprises compressed airbeing pre-conditioned to 31° C. by passage through a heat exchangerbefore being disbursed into the water through micro-dispersion nozzles;the components for monitoring, maintaining or altering the pHconcentration comprises a pH probe; the components for monitoring,maintaining or altering the salinity concentration in the range of 10-14parts per thousand comprises conductivity sensors that measure water'scapability to pass electrical flow and alert a user or make adjustmentsdirectly; the components for monitoring, maintaining or altering thedissolved oxygen level in a range greater than 4.5 mg/L comprises adissolved oxygen sensors of the polarographic, rapid-pulsing, galvanicand optical type; the components for monitoring, maintaining or alteringthe nitrogen metabolite concentration comprises sensors that alert auser; the component for monitoring, maintaining or altering the sensorto detect the modulation of surface acoustic waves to sense a physicalphenomenon comprises; the components for monitoring, maintaining oraltering the total dissolved solids index comprises sensors that alert auser; the components for monitoring, maintaining or altering the live orthe recorded visual event occurring in the tank comprises a ChargeCoupled TV (“CCTV”) camera connected.
 7. The modularized shrimpproduction system of claim 1, further comprising a high pressure waterline with a computer controlled actuator valve routed above eachproduction sub-unit, wherein high pressure water can be released intoeach production sub-unit in pulses starting from the recirculation endcap moving towards the harvest pit to facilitate harvesting of shrimp.8. The modularized shrimp production system of claim 1, wherein there-circulating aquaculture system (RAS) comprises a storage reservoirtank in fluid connection with a closed loop system; wherein the closedloop system comprises a Moving Bed Bio-Reactor (MBBR) in fluidconnection with a pump; the pump is in fluid connection with theproduction sub-unit; the production subunit is in fluid connection witha Micro-Screen Drum Filter used to remove detritus; the Micro-ScreenDrum Filter is in fluid connection with the MBBR and an Up-flowAnaerobic Sludge Blanket Reactor; the MMBR has a fluid connection to afoam fractionator used to remove emulsified proteinaceous materials fromthe water and returned the water to the MBBR; the foam fractionator hasa fluid connection to the Up-flow Anaerobic Sludge Blanket Reactor thatis used for processing and removing sludge to be used as high nitrogenfertilizer or landfill; the up-flow Anaerobic Sludge Blanket Reactor isin fluid connection with a recycled water storage tank; wherein thestorage reservoir tank is in fluid communication with a filtered naturalseawater tank or a well water tank that is in fluid connection with amixing tank used for mixing water and sea salt to a desired salinity tobe transferred to the storage reservoir tank.
 9. The modularized shrimpproduction system of claim 1, wherein the shallow water tanks andrectangular-cuboid-tanks are fabricated from materials comprising:fiberglass, wood composites, synthetic plastics, polyethylene,propylene, acrylonitrile butadiene, styrene, epoxy coated steel, metals,or combination thereof.
 10. The modularized shrimp production system ofclaim 1, wherein the shallow water tanks and rectangular-cuboid-tanksare placed inside an inter-modal container.
 11. The modularized shrimpproduction system of claim 1, wherein each rectangular-cuboid-tankscomprises multiple ports that are inserted through the tank walls toallow for placement of micro-dispersion nozzles for aeration,directional nozzles through which water reprocessed using the recyclingaquaculture system (RAS) that can be pumped to circulate watercounter-clockwise in each tank.
 12. The modularized shrimp productionsystem of claim 1, wherein the harvest pit for eachrectangular-cuboid-tanks is constructed with outlets for collection andremoval of detritus as well as harvesting of shrimp.
 13. A method forhaving a synchronous production cycle of mature shrimp using amodularized shrimp production system, the method comprising: a.preparing an aquaculture environment for a synchronous production cycleof shrimp; b. stocking post larvae shrimp in a post-larvae nurserymodule; c. raising post larvae shrimp to a juvenile stage shrimp in thepost-larvae nursery module, forming a first-phase-shrimp population; d.transferring the first-phase-shrimp to a production sub-unitrectangular-cuboid-tank; e. growing the juvenile stage shrimp in theproduction sub-unit rectangular-cuboid-tank for a first period of time,forming a second phase-shrimp population; f. dividing the second-phaseshrimp population into two separate production sub-unitrectangular-cuboid-tanks; g. growing the second-phase-shrimp populationin each of the two separate production sub-unit rectangular-cuboid-tanksfor a second period of time forming a third-phase-shrimp population; h.harvesting a portion of the third-phase shrimp population; i. dividingthe third-phase shrimp population into two separate production sub-unitrectangular-cuboid-tanks; j. growing the third-phase-shrimp populationin each of the two separate production sub-unit rectangular-cuboid-tanksfor a third period of time forming a fourth-phase-shrimp population; k.harvesting of the fourth-phase shrimp population; l. establishing asynchronous production cycle by repeating steps (a) through (k) andassuring that the production sub-unit rectangular-cuboid-tanks of themodularized shrimp production system are restocked as soon as they areemptied by the respective dividing of different shrimp populations.wherein, all shrimp growth phases and basic operations are modularizedand integrated to form a multi-phasic synchronous super-intensive shrimpproduction system controlled by a custom designed cyber-physicalplatform that acquires data through sensors embedded in post-larvaenursery module(s), grow-out production module(s), recirculatingaquaculture system (RAS) module(s), and feed distribution module(s) thatallows regulation of all aspects by Program Logic Controllers (PLCs)integrated with Human Interface Modules (HIMs) through coupled feed-backloops; wherein the shrimp growing conditions comprise: lighting,feeding, water temperature, water level, water pH and water salineconcentrations conducive for shrimp maturation; the post-larvae nurserymodule has at least one shallow-water-tank for producing juvenileshrimp, the post-larvae nursery module is in fluid connection with thefirst production sub-unit rectangular-cuboid-tank, a re-circulatingwater system (“RAS”) module, a feed distribution module, and a computercontrol module; each rectangular-cuboid-tank comprises a raisedlengthwise depth-line that is more shallow in middle of the tank with apit structure located at one end of the tank and a cap structure locatedat the other end of the tank; the rectangular cuboid tank is capable ofholding water and fitted with at least one valve for introducing andevacuating water; wherein, the re-circulating aquatic system is in fluidcommunication with the post-larvae nursery module and the productionsub-unit module; wherein the feed distribution module is in fluidcommunication with the production sub-unit module; and wherein thecomputer control module is interfaced with human interface modules(“HIMs”) and one or more equipment devices that are connected to thepost-larvae nursery module, the production sub-unit module, there-circulating aquaculture system module or the feed distributionmodule.
 14. The method of claim 13, further comprising replacing steps(k) through (l) with the following steps. (k) harvesting a portion ofthe fourth-phase shrimp population; (l) dividing the fourth-phase shrimppopulation into two separate production sub-unitrectangular-cuboid-tanks; (m) growing the fourth-phase-shrimp populationin each of the two separate production sub-unit rectangular-cuboid-tanksfor a fourth period of time forming a fifth-phase-shrimp population; (n)harvesting of the fifth-phase shrimp population; (o) establishing asynchronous production cycle by repeating steps (a) through (n) andassuring that the production sub-unit rectangular-cuboid-tanks of themodularized shrimp production system are restocked as soon as they areemptied by the respective dividing of different shrimp populations. 15.The method of claim 13, further comprising stocking post larvae shrimpat a density of 4,000-8,000/m² into each vertically stacked shallowwater tanks installed in the nursery module.
 16. The method of claim 13,further comprising preparing the aquaculture environment for asynchronous production cycle of shrimp by monitoring, maintaining oraltering: a specific light level; a water circulation rate; theshallow-water-tank water level the range of 30-50 cm; the productionsub-unit rectangular-cuboid-tank water level above 35 cm; a watertemperature in a range of 29-33° C.; a pH concentration; a salinityconcentration in the range of 10-14 parts per thousand; a dissolvedoxygen level in a range greater than 4.5 mg/L; a nitrogen metaboliteconcentration; a sensor to detect the modulation of surface acousticwaves to sense a physical phenomenon; a total dissolved solids index; avisual event occurring in the tank; a live or a recorded visual event inthe tank; or combination thereof.
 17. The method of claim 16, furthercomprising: preparing the aquaculture environment by using compressedair that is pre-conditioned to 31° C. by passage through a heatexchanger in the nursery module before being disbursed into nursery tankwater through micro-dispersion nozzles.
 18. The method of claim 16,further comprising: preparing the aquaculture environment by embeddingeach production sub-unit with sensors for water temperature, waterlevel, salinity, dissolved oxygen, pH, total dissolved solid (TDS),nitrogen metabolite levels (ammonia, nitrites, nitrates) as well asacoustics (feeding activity); wherein all physical and chemicalmeasurement data are connected via a cyber-physical platform through aProgram Logic Controller (PLC) integrated with Human Interface Modules(HIMs) for real-time feedback and adjustments.
 19. The method of claim16, further comprising: preparing the aquaculture environment by using acomputer controlled feed distribution system drawing one of fourdifferent feeds from attached hoppers; hydrating the feed; anddispensing the hydrated feed to a targeted production sub-unit based onsignal from the Program Logic Controller (PLC).
 20. The method of claim16, further comprising: preparing the aquaculture environment byembedding in each production sub-unit with sensors for monitoring,maintaining or altering the modularized shrimp production system aProgram Logic Controller (PLC) for controlling different components orprocesses of the modularized shrimp production system and is programmedaccording to the operational requirements of the system; the componentsfor monitoring, maintaining or altering the specific light levelcomprises light emitting diodes (LED's) mounted above the waterline ofeach production sub-unit; the components for monitoring, maintaining oraltering the water circulation rate comprise pumps and valves; thecomponents for monitoring, maintaining or altering the tank water levelcomprise liquid level sensors; the components for monitoring,maintaining or altering the water temperature comprises compressed airbeing pre-conditioned to 31° C. by passage through a heat exchangerbefore being disbursed into the water through micro-dispersion nozzles;the components for monitoring, maintaining or altering the pHconcentration comprises a pH probe; the components for monitoring,maintaining or altering the salinity concentration in the range of 10-14parts per thousand comprises conductivity sensors that measure water'scapability to pass electrical flow and alert a user or make adjustmentsdirectly; the components for monitoring, maintaining or altering thedissolved oxygen level in a range greater than 4.5 mg/L comprises adissolved oxygen sensors of the polarographic, rapid-pulsing, galvanicand optical type; the components for monitoring, maintaining or alteringthe nitrogen metabolite concentration comprises sensors that alert auser; the component for monitoring, maintaining or altering the sensorto detect the modulation of surface acoustic waves to sense a physicalphenomenon comprises; the components for monitoring, maintaining oraltering the total dissolved solids index comprises sensors that alert auser; the components for monitoring, maintaining or altering the live orthe recorded visual event occurring in the tank comprises a ChargeCoupled TV (“CCTV”) camera connected.
 21. The method of claim 16,further comprising: harvesting shrimp using high water pressure linesrouted above each production sub-unit and connected to computercontrolled actuator valves activated in pulses starting from therecirculation end cap moving towards the harvest pit.